Composite article and method of preparing same



. 5. BROWN COMPOSITE ARTICLE AND METHOD OF PREPARING SAME Filed Jan. 15,1924 Patented Jan. 214 1925. I

' UNITED STATES PATENT, OFF

SANDFOBD BROWN, OF MONTGLAIR,

IPOBATION, OF NEW YORK, N.

1,524,335 ICE.

NEW JERSEY, ASSIGNOR TO BAKELITE COB- Y., A CORPORfiTION OF DELAWARE.

GOIPOSITE'AB'IIGLE AND METHOD OF PREPARING SAME.

Application filed January 15, 1924. Serial no. 686,469.

To all whoin it may concern.

Be it known that I, SANDFORD BROWN, a citizen of the United States; andresident of Montclair, county of Essex, and State of New Jersey, haveinvented certain new and useful. Improvements in Composite Articles andMethods of Preparing Same, of which the following is a specification.

e invention relates to improvements in composite articles and method-ofpreparing same and particularly to articles formed of phenoliccondensation products having secured thereto wood or other fibrousmaterial of a nature not adapted to be secured directl to thecondensation product article by t e useof a cold adhesive, and methodsof formin the same.

Difficulties often arise when it is desired to make use of a phenoliccondensation product for the formation of a part which must have securedthereto a strip or piece of wood, or the like. Wood and similar fibrousmaterials cannot be surface of an article formed of an infusiblephenolic condensation product, by the use of the usual adhesives, suchas glue applied in the manner customary in securingtwo heat.

-uct article, but this cases because of the fact that the pieces, forexample, of wood, together, that is by simply applying the" adhesive tothe members which are to be joined and allowing the adhesive to set.such casewill not form a bond, or a sufficiently tenacious bond, withthe surface of full the condensation product article. It is sibletoformsuc (posa joint by a metho in which a considerable amount of heat isused in which case the adhesive will form a considerable bond with-thecondensation prodis :not feasible in many wood or other fibrous materialis warped, or otherwise in'uriously affected by the applied ISO, in manycases, as Where the wooden part-must be'true and exact inform, thedesired composite article cannot be made by inserting the wood into themould as an insert in t e condensation product article during themoulding and reaction under heat of the material which forms thecondensation product, because of the fact that the heat would warp thewood, etc. Such a method also would be impractical in many cases becauseof the fact that the wooden member would be too long'or too large to beincluded in the mould.

secured directly to a' article of manufacture.

article when the I overcome these difficulties by moulding thecondensation product article with a strip of absorbent fibrous orcellular material, such as paper, pressed against a surface of thereactive material in the mould. This strip will accordingly beautogenously' secured to the moulded condensation product reaction iscomplete and the condensation (product article is completely moulded. tthe same time the o posite' side of the strip will remain absor out, sothat it will take glue or other adhesive well. After removing thearticle with attached strip from the mould, the desired member of wood,or the-like, is firmly secured to the condensation product article bygluing the wood, by the use of any suitable cold adhesive, to the striwhich is antogenously secured to the cond nsation product article. v

The invention accordin 1y comprises a process of the character re erredto and the compositearticle formed thereby as a new. The objects of theinvention comprise the provision of such a process and various processsteps employedtherein and the provision of an improved .The adhesive inarticle of manufacture of the character indicated, in which the wood orsimilar fibrous or cellular material joined to the condensation productarticle is unwarped or otherwise injuriously afi'ected, all as will morey appear in the following'sp'ecification, the invention being moreparticularly pointed out in the appended claims. In order that theinvention may be more clearly understood attention is hereby directed tothe accompanying drawings forming part of this application andillustrating, by way of example, the method of forming a piano key, orthe like, of a phenolic condensation product, and securing the same toawooden lever member. In the draw mgs Fig. 1 is a sectional view througha mould in which the condensation product material is to be moulded witha strip of absorbent paper pressed against one face thereof;

Fig. 2 is a. side elevation of the moulded piano key with thestrip ofpaper autog-- enously secured thereto, and f Fig. 3 is a side elevationof the, piano key after the wooden. glued to the p'a. r strip,

lever member has been. i

- The moulded 1, or object which is to be secured to a .wooden or otherfibrous member of the character referred to, is formed-of an infusiblephenolic condensation product. This article 1 is moulded in the usualway in a mould 2,

are placed in the mould as indicated at 3.

These ingredients may comprise one of the usual moulding mixturescomprising substances which react on application of suffi- 'cient heatto form an infusible phenolic condensation product with or without theaddition of suitable filling material, all as is well known. Themouldinmixture may comprise, for example, a fusib e phenol resin having amethylene-containing hardening agentmixed therewith, together with asuitable proportion of filling material, such as wood flour.

The strip 4 of absorbent paper or the like is placed in the mould on topof the ingredients placed therein, or otherwise, in position to pressagainst the surface of the moulded article which is to be joined to thewooden or fibrous strip. When the mould is closed this paper strip willbe pressed against the surface of the material in the mould. Uponapplication of heat and ressure in the usual way, the ingredients willreact to form an infusible insoluble phenolic condensation product ofthe desired form with the paper strip autogenousl of, as is indicate inFig. 2.

article when completed is removed from-the mould and a suitable adhesiveis applied to the strip 4 or to the wooden member 5, which is to bejoined thereto, or to both, the wooden member 5 is 'pressed into closeengagement with the strip 4 and the glued joint is allowed to set in theusual wa Any suitable cold adhesive suitable or 'oining together wood anpaper or the li e may be used. The wooden strip 5 in the form of theinvention shown in the drawings, is a wooden leverwhich extends backfrom the piano key as part of the 1ano action. It is evident that thiswoo on member is secured firmly to the condensation product piano ke andthat the wood has not been subjecte to warping or any other harmfulaction in the process by which the parts weresecured together.

It will be noted that in my process the absorbent strip of paper or thelike bonds 'firmly to the condensation product article,

during the molding of the latter, by the condensation product enteringto some extent into, or fastening firmly to, the adjacent surface of thepaper, without, however, flowing entirely through or impregnatin thepaper. Accordingl the'opposite si e of the paper remains su cientlporous and absorbent to take glue well. e paper joined to a surfacethere= is completed, removing the in them should be sufliciently thickand of suficient body to prevent the condensation product material,prior to its final hardening, penetrating entirely through the same. Thethicknem required will difier in accordance with the character of thepaper, but may be from 5/1000 to 10/1000 of an inch thick, for example,or somewhat thinner in some cases. The process is best practised with amolding .mixture or material which does not become thinly fluid duringthe molding operation.

It should be understood that the invention is not limited strictly tothe exact details of process and construction of the article otherwisethan as is indicated by the accompanying claims.

What I claim is:

1. A process of forming a composite article, comprisin placing in asuitable mold materials a apted to react on ap lication of heat, to forma hard infusi le phenolic condensationroduct, placing a strip of fibrousor cellu ar material in the mold, in position to bear against a surfaceof the confined reactive -material when the mold is closed, moldin thematerial under heat and pressure whi e pressing the said strip against asurface of the same, to form a desired article of infusible phenoliccondensation product with said stri adhering thereto, and thereaftersecuring, y the use of suitable adhesive, wood or other fibrous materialto said strip.

2. A process oft forming a composite article, comprising, molding ahenolic condensation product article wi a stri of paper pressed againsta surface thereo in the mold, so as to adhere to the molded article, andsecuring a wooden member firmly to said strip by a cold adhesive.

'3. A process of forming a composite article, comprising, molding ahenolic condensation roduct article wit a strip of absorbent brous orcellular material ressed against a suface thereof, in the mol so as toadhere to the article when the molding same from the mold, and securingto said stri by the am of a cold adhesive a member i ormed of a. fibrousmaterial of a nature not adapted to be secured directl to said moldedcondensation product y the use of a cold edhesive.

4. A process of forming a composite article, comprising, molding a pianokey with a strip of absorbent fibrous or cellular material ressedagainst. surface thereof,

o ld, so as to adhere to the molded key when the molding is completed,removing. the same from the mold, and securing a wooden key lever memberto said strip, by the use of a cold adhesive.

5. As a new article of manufacture, an

article formed of an infusible phenolic condensation product having astrip of absorb- 7. As a new .article of manufacture, a 1 ent fibrous orcellular material autogepiano key formed of an infusible phenolic nouslysecured to a face thereof, with amemcondensation product having a stripof abber secured to said strip by adhesive, said sorbent fibrous orcellular material auto- 5 member being formed of a material not genouslysecured to a face thereof, with a adapted to be directly secured to saidconkey-lever member secured to said strip by 20 densation product by theuse of a cold adadhesive, said member bei formed of a hesive. f materialnot adapted to be irectl secured 6. As a new article of manufacture, anto said condensation product by t e use of 10 article formed of aninfusible, phenolic cona cold adhesive.

densation product having a strl of absorb- In testimony hereof I havesigned my 25 ent paper 'autogenously secur to a face name to thisspecification. thereof, with a wooden member secured to e said strip byadhesive. SANDFORD BROWN.

